Carbonate manufacture



April 11, 1961 T. c. MILLER CARBONATE MANUFACTURE 2 Sheets-Sheet 1 Filed NOV. 28, 1958 mm 0. mm 0m 91 x mm; 4 om 0 mm; o x oo m Jom m 2 JNVENTOR. Thomas C. Miller BY ATTORNEY 2 Sheets-Sheet 2 Filed Nov. 28, 1958 Fig.2

O O O o x o\ 62:39 3555 QEHEm KY F 24 HOURS 0 IO 20 3O 4O 5O 60 TIME (MINUTES) FROM TIME GEL FORMED TO TIME GEL DISRUPTED INVENTOR. Thomas C. Miller ATTORNEY CARBONATE MANUFACTURE Thomas C. Miller, Tonawanda, N.

Filed Nov. 28, 1958, Ser. No. 776,878

12 Claims. (CI. 23-66) cosmetics, and other manufactures requiring fine fillers,

extenders, etc. This application is a continuation-in-part of my copending application Serial No. 597,516, filed July 12, 1956, now abandoned.

The causticizing of Na CO with Ca(OH) is carried.

out in various ways, depending upon the end use for the NaOH liquor and/or the CaCO presipitate. Thesoda pulp and the sulphate (kraft) pulp industries interested only in the NaOH liquor presently execute the causticization with warm or hot solutions of Na CO and suspensions of Ca(OH) The precipitate producedv under these conditions is separated by sedimentation and either reclaimed by reburning or wasted through the sewer. Soda plants interested in a coating material generally operate a separate division for the preparation of precipitated CaCO in which hot suspensions of Ca(OH) are used to causticize hot solutions of Na CO The latter process requires first stage filtration by vacuum, resuspension of the precipitate in hot H O followed by recausticizing with hot Na CO and refiltering (second stage) the precipitate to obtain complete removal of Ca(OH) as CaCO The precipitate for coating must not contain any free Ca(OH) hence the necessity for two-stage causticizing The warm or hot causticization of Na CO presents two objectionable features. First, precipitates of CaCO constant in particle size distribution or specific surface are difficult to obtain apparently because of variations in temperature and concentration of the reagents and second, a resuspension and recausticization of the CaCO precipitate further complicates the particle size distribution by promoting agglomeration. Agglomerated particles produced in this manner are very difficult to redisperse as individual particles even atextremely high speed agitation or high energy dispersion.

Cold causticization in the range of 20 C. to 75 has been previously discussed very broadly, for example, US. Patent 2,062,255, issued November 24, 1936, wherein a recognition is made of the relatively finer CaCO particle size produced thereby. Cold causticization has not, however, replaced the warm causticization process due to certain other even more objectionable features. 015 prime importance is the lack of recognition, heretofore, of a t fi iQ 7 i? 2,979,380 Patented Apr. 11, .1961.

cold causticization process susceptible to a commercially suitable rate of separation of precipitate. Separation by sedimentation of the very fine particle precipitates is far too slow for commercial practicability. Filtration of the precipitate of cold causticization has been impractical due to the lack of a product of suitable uniform particle size distribution and method for producing the same.

It is an object of the present invention to provide a method of producing precipitates of CaCO by cold causticization, which method avoids the above mentioned objectionable features, and produces, in highly repro-' ducible form, a precipitate of CaCO of unusually uniform particle size, that is, precipitates of unusually narrow particle size distribution, which method is, further, subject to controllable variation in a relatively wide range of selective fine particle sizes. t,

It is a further object of the invention to provide an improved, extra fine CaCO powder of superior characteristics heretofore unavailable. I

These and other objects of the invention will be more readily apparent when considered in relation to the preferred embodiments as set forth in the specification and further disclosed in the drawings, in which Fig. 1 is a graphic representation 'of specific surface of the products, embodying the invention, in relation to the temperature of c'austicization, at various ratios of reactants, all in accordance with the process of the invention, and Fig. 2 is a graphic representation of specific surface of the products, embodying the invention, in relation to the time. of gel maintenance.

of time, or during a specified time.

vert about of the Na CO to NaOH. The gelled mass is then dispersed by agitation and the suspensionof CaCO in NaOH solution is filtered by vacuum to remove the NaOH. The precipitate of CaCO contains some- Ca(OH) because the reaction is not complete in strong NaOH solutions or when insufiicient Na CO is present. But, the Ca(OH) is converted to CaCO by washing this precipitate in filter cakeform with a solution of Na CO maintained at the same temperature at which the causticization was originally carried out. The

precipitate of CaCO is then washed with fresh water until it is free of alkali. The precipitate will. be found to be free of Ca(OH) EXAMPLE ,I

A typical causticization, in accordance with the invention, may be made with 1000 ml. of Ca(OH) suspen sion of 175 g.p.l. (grams per liter) and 1000 ml. of Na CO of 200 g.p.l. The Ca(OH) suspension is first sieved through a sieve, of from to 250 mesh, to remove impurities. The Na CO solution is then added substantially all at once to the 1000 ml. of Ca(OH) suspension, both being at 20 C., in a 3 liter beaker, 8

inches in diameter, and agitated with a two-arm crossstirrer'operated at 140 r.p.m.

EXAMPLE II The 20 C. Na CO solution may alternatively be added to the 20 C., Ca(OH) suspension through an orifice, delivering the 1000 ml. of Na CO solution of Example I in approximately 12-14 minutes, while the Ca(OH) suspension is agitated at 140 rpm. The reaction, maintained throughout at 20 C., will be completed sufficiently to form a pseudo-gel in approximately 20 minutes, plus or minus 3 minutes, from the time the first Na CO is added to the Ca'(OH) EXAMPLE III For a reaction with the chemicals maintained at 40 C., the Na CO solution may be added through an orifice tube, delivering the 1000 ml. in not more than 2 minutes, the conditions otherwise being as defined in Example I. The gelling will be found to take place in approximately 4 minutes from the time the first Na CO is added to the Ca(OH) at this temperature.

Continuing the process of each of the above examples, agitation is stopped at the moment gelling begins. This gelled suspension is allowed to remain undisturbed until the reaction has converted approximately 90% of the Na CO to NaOH. The time required for sufficient effect of the reaction in the gelled suspension condition, in order to obtain a definite marked improvement in the resultant CaCO in accordance with the invention, is about fifteen minutes. In the present example of the invention the suspension is maintained in the gelled condition a period of about one to one and one-half hours. Any additional time allowed at this step of the process, even several days, has been found to have no measurable technical disadvantages.

The gel is dispersed by agitation when the reaction has reached the desired efficienc'y and the suspension is filtered through a vacuum filter. In the methods of the Examples I to III above, a standard 4 /2 inch Oliver- United test filter leaf was employed. The filter leaf was provided with a nylon filter cloth and operated under a vacuum of 24" of Hg. The assembled filter was placed in the suspension at the required vacuum and operated for exactly one minute. Filter cakes of approximately 1% inches were obtained from the suspensions of the 20 C. reactions of Examples I and II, and filter cakes of approximately inch were obtained from the suspension of the 40 C. reaction of Example III.

The precipitated CaCO containing some Ca(OI-I) is Washed with 1000 ml. of a Na CO solution at a concentration of 100 g.p.l. and at a temperature of the causticization. The precipitate is finally washed with fresh water until free of alkali, or until ml. of the filtrate requires not more than 1 drop of N. HCl to neutralize it to methyl orange indicator. Not more than three volumes of fresh water will be required for each volume of dispersed suspension to complete this washing.

The Na CO wash solution will be converted to a NaOH solution of approximately the same concentration as the white liquor, with which it is combined as white liquor. The CaCO precipitate will be found to be substantially free of Ca(OH) EXAMPLE IV Commercial volumes of CaCO may be prepared by slaking 3680 pounds of quicklime (CaO) in 3500 gallons of water, or water containing as much as 4 g.p.l. NaOH, to produce a suspension of Ca(OI-I) which is subsequently sieved through from a 100 mesh to 250 mesh sieve to remove impurities. The sieved suspension will contain 175 g.p.l. (1.46 p.p.g. or pounds per gallon) Ca(OH) when cooled to room temperature. The sus pension of Ca(OH) is cooled to some temperature between 20 C. and 40 C., in the present example 25 C. A 3000 gallon Na CO solution at a concentration of 258 g.p.l. (2.15 p.p.g.) and at the same 25 C. temperature, is pumped in 12 minutes into an eleven foot diameter tank containing the Ca(OH) while the mixture is continuously agitated by an eleven foot diameter twoarm cross-stirrer, rotated at a speed of 9 rpm. Gelling. occurs in approximately 20 minutes .after the first Na CO is added to the Ca(OI-I) The gelled mixture is allowed to remain undisturbed for approximately 1 /2 hours. The gel is then dispersed by agitation and the liquor filtered by vacuum filtration.

The precipitate is then washed with 3000 gallons of water containing 100 g.p.l. (0.83 p.p.g.) Na CO to convert any remaining Ca(OH) to 0.100 Finally, the precipitate is washed with fresh water until the filtrate is free of alkali.

The Na CO wash liquor will be found to have a concentration of NaOH equivalent to white liquor and consequently can be combined with the original NaOH filtrate as cooking liquor in the pulp industry.

The precipitate consists of particles of uniform diameter CaCO having a specific in the order of 79,000 cm. /g. and is, for all practical purposes, free of Ca(OH) 'Specific surface measurements of Ca(OH) and CaCO powder included herethroughout have been obtained with the Blaine air permeability apparatus (ASTM C204-50).

EXAMPLE V In the preceding examples the gel was maintained for approximately one .to one and one-half hours. In the present example suspensions formed according to either Examples I or II, are allowed to form a pseudo-gel maintaining quiescence for fifteen minutes, agitation being stopped the moment gelling begins. When the gel has been maintained undisturbed for a period of about fifteen minutes, the reaction will have converted almost 90% of the Na CO to NaOH and substantially all of the CaCO will have been formed in accordance with the invention.

The gel is then dispersed by agitation and the suspension is filtered and washed as described in Example III.

Ca(OH) preparation The most important prerequisite for a suitable calcium carbonate precipitate is the type or quality of CaO used to produce a suspension of high quality Ca(OH) The lime '(CaO) must be capable of producing small diameter particles or a high specific surface Ca(OI-I) The highest specific surface Ca(OH) is obtained when CaO is slakedin an excess of water, in the order of 6 or 7 parts by weight of water to one part CaO, at or near 100 C., because maximum activity between water and lime is thus-obtained to explode particles into minimum dimensions. Aged or air-slaked lime or improperly calcined lime will not attain sufficient fineness and, consequently, will not be suitable for producing the coating carbonate, in accordance with the invention. A CaO suitable for coating-grade CaCO should develop a Ca(OH) of not less than 48,000 cm. g. surface. The Ca(OH) specific surface is determined with the Blaine apparatus by making five separate charges of the powder produce a good Ca('OH)' is that the temperature riseat --1east.28" C. by 30 seconds and at least-45 C. at the maximum temperature. I

It has been found that the ratio of Ca(OH) to Na CO is very important and critical in developing a pigment CaCO ofdesired specific surface, uniform particle size, and other physical properties in accordance with the invention. It is necessary to accurately determine the quantity of Ca(OH) in suspension chemically, by the sugar method or otherwise, and maintain the quantity in definite proportion to the water present.

The Ca(OH) concentration is most satisfactory at approximately 175 g.p.l. (1.47 p.p.g.) to 194 g.p.l. (1.62 p.p.g.) corresponding to a H O to Ca(OH) weight ratio of approximately 4.7 to 4.15. These weight ratios correspond to a H to CaO weight ratio of approximately 5.6 to 6.3. More concentrated suspensions cannot be satisfactorily screened through the customary screen cloth to remove impurities. pensions in the process of the invention produce liquors low in NaOH. The important factor establishing this ratio is the control of particle size and the filtering efliciency of CaCO produced from it in accordance with the invention.

A chemical analysis of the Ca(OH) suspension is essential in determining the critical amount of Na CO required in the process of the invention. This Ca(OH) analysis is readily accomplished by treating 5 ml. of the suspension in ml. of water with 25 ml. of a 50% solution of cane sugar. After 10 minutes, the mixture is titrated with normal HCl to a phenolphthalein end point. The quantity of acid required multiplied by 7.41

- will give the concentration of Ca(OH) in grams per liter of suspension. A concentration in grams per liter may be divided by 119.8 to give the concentration in pounds per gallon.

The raw material source for the Ca(OH) of the present process has been found to be not critical for practicing in accordance with the invention, however, a high calcium lime is clearly preferable and advantageous and has been used for obtaining all data disclosed herein. When a high magnesia lime hydrate or dolomitic lime hydrate is used in the process of the invention, all proportions taught herethroughout should be based upon the Ca(OH) portion only of the hydrate. With regard to the precipitation reaction under the conditions of the novel process, the balance of the hydrate, in the form of MgO or Mg(OH) has been found to he apparently relatively inactive. The presence of the MgO or Mg(OH) does not inhibit the reaction of the prescribed ingredients in their normal manner as herein set forth other than to reduce the resultant specific surface of the product generally in proportion to the ratio in which the MgO or Mg(OH) is present in the hydrate.

Na CO preparation The concentration of Na CO solutions should be as high as practically possible to produce a high concentration of NaOH in the resulting liquor. Regardless of the low efficiency of concentrated solutions of Na CO and suspensions of Ca(OH). it is desirable in most cases to maintain high concentrations and to overcome the low efiiciency by other provisions in the process. The solubility of Na CO in water between 20 C. and 40 C. is then the only factor governing the possible concentration of a solution. Naturally, a solution of Na CO should contain no solid phase, else the possible presence of Na CO -1OH O will interfere with the reaction.

Theoretically, a saturated solution of Na CO at 20 C. contains 213.5 g.p.l. (1.78 p.p.g.) Na CO The concentration of the solution at this temperature, in accordance with the invention, should be maintained at approximately 200 g.p.l. to 210 g.p.l. to avoid the presence of a solid phase. Preferred concentrations will be higher at higher temperatures, in accordance with the invention,

'- increasing toapproximately 429 g.p.l. at 40 C.

And, the use of more diluted sus- J 6 The actual concentration of .Na CO in asolution for reaction should be determined by titration to accurately proportion the reagents. A sample of 10 ml. of the solution titrated with N. HCl to methyl orange indicator and the titration multiplied, by 5.3 will give the concentration in grams per liter.

While a concentration of 200 g.p.l. to 210 g.p.l. Na CO may be sufficient to produce the desirable quality of CaCO it may be desirable to provide a greater Weight of Na CO to increase the concentration of a resulting NaOH solution (white liquor). The presence of Na CO -10H O in the Na CO solution is detrimental to the proper gelling and crystallization of CaCO of the proper particle size and therefore the solubility of Na CO .limits the maximum concentration. However, when it is desirable to increase the concentration at low temperaa causticized suspension before gelling has taken place. The total volume of water from the Na CO solution and the Ca(OH) suspension then provides ample liquid for the solution of this additional Na CO without the formation of Na CO '10H O.

Causticization reaction The common reaction between Ca(OH) and'Na CO is not a simple one. A NaOH solution is produced from the reaction and, because of its high ionization, the reaction tends to be reversed so that generally the efiiciency of the reaction is 90% complete. Diluted solutions of more complete reaction, but the concentration of the resulting NaOH solution is far too low to be of commercial value in many industries including pulp and paper. In present day commercial practices, this reaction is usually carried out at high temperatures in the order of 100 C. More concentrated solutions of Na CO and more concentrated suspensions of Ca(OH) are generally reacted at such high temperatures in a single reac-- tion when the presence of Ca(OH) in the precipitate is not objectionable. Or, the reaction is carried out at the high temperature aiming for maximum conversion followed by a second reaction of the precipitate with a second solution of Na CO to remove all Ca(OH) from the precipitate as CaCO when Ca(OH) is objectionable. Maximum conversion of Na CO to NaOH and Ca(OH) to CaCO in these reactions has been obtained when the Ca(OH) is approximately 10 percent in excess. of these reactions consistently produce a precipitate of uniform particle side or high filtering efficiency because of the high temperatures and because of the resuspension and recausticization. This causticization reaction has, however, now been carried to approximately 96% with the present cold method of causticizing.

Inorganic reactions generally take place almost instantaneously at room temperature. They are accelerated at higher temperatures (near boiling100 C.), but it is a well-known phenomenon in analytical chemistry that boiling accelerates the formation of larger particles by agglomeration. This is analogous to a causticization reaction carried out at higher temperatures. The formation of agglomerates produces particles of various sizes will not be completely instantaneous, but will take place in an-orderly fashion to govern the size of particles predominant in a definite size range. The object of such a reaction would be to produce particles of substantially uniform diameter with a of particles finer or Neither :coarser "than the average-sized "particles; The :particles being more or less of uniform size would not correspond with the probability curve for particles covering a wide range of sizes. Particles of more or less uniform size pack into a bedwith a maximum of void space (minimum of packing) to offer the least resistance to the passage of liquids. Therefore, the filter rate of such a bed of particles will be very high.

The reaction between Ca(OH) suspensions: and Na CO in accordance with the process of the invention results in a pseudo-gel of good stability. These gels are produced after various lengths of time of mixing depending upon the temperature of the reagents between 20 C. and 40 C. The .reaction at 20 C. produces a gel in approximately 25 minutes after the chemicals have been combined, while the reaction at 40 C. produces a gel in approximately 4 minutes. Controlled temperatures between these limits produces gels at proportionally corresponding times. The particle size, as determined by the Blaine air-permeability method, varies inversely as the time elapsed before gelling, the longer the gelling time, the finer the carbonate produced, and the shorter the gelling time, the coarser the carbonate. When the reagents are combined in the proper proportions, sufficiently before the gel time, the reaction has been found to produce a gel uniformly throughout a mass, regardless of size, at the proper time. When gelling begins, the reaction is spontaneous and only a few seconds are required for complete solidification of the mass to such a consistency that a motor-stirrer can be stalled or stopped. Undercontrols of temperature, concentration, chemical ratio and agitation the timefor gelling between 20 C. and 40 C. can be consistently reproduced. The particle size or specific surface being governed by the gel time is also a function of temperature so that the specific surface is dependent upon temperature of the reaction.

A study of the development of CaCO precipitates at temperatures above 40 C. has been made. Although the specific surface of carbonate precipitates continue to decrease With an increase in temperature from 40 C. to 100 C. (see Table VII), the gelling phenomenon does not occur at 50 C. and above. Most likely, the absence of the gelling characteristics at these temperatures above 40 C. is the result of an almost immediate or instantaneous gelling upon the instantaneous mixing of the reagents which would be overlooked or otherwise occur unnoticed even at gentle agitation. The decrease in gelling time from approximately 25 minutes at 20 C. to approximately 4 minutes at 40 C. indicates the approach to an instantaneous gelling time slightly above 40 C. The successful production of high specific surface carbonates depend upon the development of gels at various temperatures for consistently producing a reproducible specific surface at these temperatures. The gels must be allowed to form without interference from excessive agitation and, Where thickening or gelling does not occur, control of constant specific surface is less likely.

The reaction between Ca(OH) and Na CO can be controlled to produce a gel of maximum specific surface and minimum uniform particle size diameter by maintaining a definite excess of Ca(OH) As stated above, the reaction between Ca(OI-I) and Na CO reaches a maximum of approximately 90 percent because of the high ionization of the NaOH produced. The reaction may be improved by an excess of Ca(OH) 2 over the stoichiometric requirement. This is generally maintained at approximately percent excess CaO in prior Warm causticization processes. It was found, in accordance with the present invention, that definite excesses must be present if the Ca(OH) is to act not only as an improvement to the chemical efiicienc but also as a catalyst in assisting in the control of the specific surface of particle diameter. A definite excess of Ca(OH) provides an efficiency of up to approximately 96 percent, and prevents a prema- .ture: reaction between the Ca(Ol-l) and Na CO until gelling. Ca(OH) must be present in the amount of at least 2% over the stoichiometric amount to achieve favorable results, and it may be present to the extent of 40 percent in excess of stoichiometric amount withoutetfecting maximum specific surfacen The excess Ca(OH) present in'the precipitate is not detrimental to the :quality of be less than 1.43.

the CaCO because it can be subsequentlyreactedwith a wash solution of Na CO atthe originalreactionitemperature to convert it to CaCO Therefore, Ca(OI-I) in excess of the amount required for stoichiometric reaction improves the chemical and physical efiiciency of the process and can be subsequently converted 100 percent to use ful CaCO The optimum reaction between Ca(OH) and .Na CO takes place when thereagents are maintained at a weight ratio of Na CO /Ca(OH) of approximately 1.20. The weight ratio for theoretical proportions of 'Na CO- 'and Ca(OH) is 106/741 or 1.43. It is necessary to maintain an excess of Ca(OH) to develop the CaCO at a maximum specific surface, and therefore the practical ratio will Ithas been found that Wlthiil'illll'lltS this optimum ratio is from 1.00 to 1.40. Table Iillustrates the amount of reagents for laboratory procedures when the weight of Na CO isv held constant :and the weight of Ca(OH) varied to produce the requiredratio of concentration.

TABLE I Weight Theoret- N11200:, Ca(OH)2, Ratio, ical Excess Percent g. g. N21200:] Ca(OH)2 Oa(OH)r Excess Ca(OH)z Required, Weight Ca(OH)2 The results of the improper weight ratio of the Ca (OI- to Na CO indicating a deficiency of Ca(OH) is illustrated by the following example. The stoichiometric weight ratio of Na CO to Ca(OH) is 1.43. At this ratio the reaction is only complete because of the tendency for the reaction to proceed in a reverse direction caused by the high ionization of NaOH. However, under the influence of variations in concentration and temperature, this reaction may proceed to a higher efficiency and from a theoretical standpoint a 1.43 ratio should be considered a maximum. When this weight ratio was increased to 1.458 the specific surface of the CaCO was greatly reduced, which affected the filtering rate of the carbonate. Table II shows a comparison in the specific surface and the filtering rate of this carbonate compared to a carbonate produced at the same temperature at a ratio of 1.40, indicating the inferior quality of carbonate produced.

The development of a carbonate of the proper particle size or specific surface, produced by the causticization, is also influenced to a great extent by the weight ratio of total calculated solid materials, Na CO plus Ca(OH) to the total volume of the suspension. This is another way of expressing the weight ratio of calculated solids to liquid. It has been found thatthis weight ratio is. asimportant as the weight ratio of Na CO to Ca(OH) in producing material of optimum or maximum specific surface. Very little consideration has been given to the ratio of solids to liquid in commercialwarm causticizations, probably because. the

ratios are less sensitive or less applicable at high tem-' peratures. However, reactions carried out at low temperatures, in accordance with the present invention, are much more sensitive to this ratio in 'developing a cargreeof reaction may take place between the- Na CO,

and the Ca(OH) before the gel time of approximately 25 minutes. The process as otherwise herein defined will result in failure where gelling takes place before all may be added to a solution of Na CO to produce a carbonate with the novel desirable properties, it is clearly preferable that the solution of Na CO be added to the suspension of Ca(OH) It is important that the rate of adding these ingredients together or the method of mixing be closely governed to produce a stable pseudogel. The point of gelling is definite for each temperature between 20 C. and 40 C. and varies inversely in this temperature range. That is, causticizing at 20 C. produces a gel in approximately 25 minutes and causticization at 40 C. produces a gel in approximately 4 minutes. It is necessary that all Na CO is introduced into the Ca(OH) suspension before this gel point is reached. It is further desirable that all the Na CO be introduced into the Ca(OH) well before this point is reached. Consequently, the Na CO may be added at one time, instantaneously, at the beginning of the process or it may be added in uniformly controlled rates. The ideal time for adding the Na CO is estimated to be one-half the time required to reach the gel point. That is, at 20 C., the Na C shouldbe added in approxi "'tnat'ely 12' to 15 minutes in order that the optimum debonate of maximum specific surface. The ratio of solids the Na CO solution has been introduced. Any portion to liquid cannot in itself be attributed to controlling the of the Na CO solution not introduced into the Ca(OH),

specific surface but this ratio in definite combination with before gelling does not enter into reaction and consethe weight ratio of Na CO to Ca(OH) with other quently, no physical or chemical reaction is obtained defined conditions, produces a combination for explicitly with this portion of the solution, destroying the uniform controlling the specific surface. fine particle distribution of the product.

The designation R is used hereinafter for convenience The particle size or the specific surface of CaCO can in expressing the weight ratio of Na CO to Ca(OH) be controlled very closely from approximately 35,000 and R is used for conveniently expressing the weight cmP/g. to more than 120,000 cmF/g. at the foregoing ratio of the total volume of suspension to the calculated concentrations, rates of addition and rates of agitation weight of solids present. Maximum specific surfaces, by controlling the temperature of both the Ca(OH), with uniform particle size distribution, have been obsuspension and the Na CO solution. It has been found tained, without a sacrifice in the quality of the NaOH that the specific surface of precipitated CaCO varies produced, when R, ranges from 1.0 to 1.4 at the same inversely as the temperature of causticizing. That is to time R ranges from 5.1 to 5.8. Table III presents say, a maximum specific surface is obtained ata causdata to illustrate the influence of the ratio, when all ticizing temperature of 20C. (68 F.) and the specific other factors are controlled and the reactions were made surface decreases at a given rate as the temperature is at a Na CO /Ca(OH) weight ratio of 1.2 and 1.0. increased to 40 C. (104 F.).

TABLE III [Temperature 20 0.]

R Ca(OH)1+ Total Vol. R1 Ratio, Specific Ca(OH);|, Na co Nmcoa Na CO3, Suspen- Total Vol. Surface, wt. wt. m wt. slon, ml. Ca(OH)z+ cmfilg.

Nazooa 77.8 93. 5 1. 2 171. 3 1. 040 0. 00 03,100 194. 5 233. 5 1. 2 42s. 0 2, 120 4. 95 85, 404 171. c 205. 0 1. 2 377. 5 2,058 5. 45 113, see 154.0 184.9 1.2 338.9 1,800 5.31 113.968 75. 4 75. 4 1. 0 150.8 5 5. 6 113, 011

Therefore, the weight ratio between the total volume Table IV and Figure 1 show the specific surface of of the suspension and the calculated solids as Ca(OH) CaCO precipitates obtained in the temperature range and Na CO must be in the order of 5.1 to 5.8 in order of 20 C. to 40 C. where R varied from 1.20 to 1.40. to develop a product of maximum specific surface of A combination of the ratio for R and the temperatures uniform particle size. 40 within these ranges will therefore permit the production The fineness of a calcium carbonate precipitate, proof CaCO at a predetermined specific surface. duced in accordance with the invention, can also be controlled by regulating the temperature of the Ca(OH) TABLE IV l? and Nazcos between fiiiiilfiffioiiii fiil313%?fib ifiioi afiiiigf33 23132 and 40 C. when all other factors are constant. The turesfmm C specific surface area of CaCO produced varies inversely 45 as the temperature of these chemicals vary, and can be Temperature, 0. produced in a range of 120,000 cmP/g. to 35,000 cmP/g. Ram R1 (Blaine) by contr0l1ing the process plus or minus 1 20 in this range.

The method of mixing the chemicals at any stipulated 111,093 101. 942 74,600 52, 330 42,910 temperature must be executed by a prescnbed procedure. ig ggl 25:23? 23, 32 g; g; Wh1le I have found that under certain additional some- 103,096 85,772 55,341 45,335 36,287

what impractical conditions a suspension of Ca(OH) 1001485 88344 561104 401481 34355 Rate of agitation The rate of agitation during the addition of the Na CO solution to the Ca(OH) suspension is the most important factor contributing to the formation of a gel of properlysized CaCO particles when the concentration and temperature of the reagents are held within the limits specified above. The agitation rate must be sufficient to keep the suspension of Ca(OH) dispersed in the Na CO solution so that particles of Ca(OH) will not settle out. The agitation must not be great enough to cause severe turbulence. Excessive agitation accelerates the reaction between Ca(OH) and Na CO to form CaCO and this condition promotes premature gelling. Premature gelling greatly reduces the specific surface, increases the'rchange iITTSPEClfiQs surface or gparticlesizezresulting from the premature gelling.

t normal gel with the 8" container was found to be within the range of 70-185 rpm. and preferably 140 r.p.m. Larger vessels have been used in experimental laboratory and commercial equipment to make production quantities. Agitation with equivalentdesign but larger diameter, stirrers has been found satisfactory so long as peripheral speed of stirrers is maintained in the order of from 140 to 390 feet per minute. The mathematical formula for determining the-properspeed of all such largerstirrers is:

. where S 140 r.p.m., is the stirrer speed used in the experimental vessel ofradius, R 4 inches, and S is the stirrer speed to be used in a vessel having a radius, R expressed in inches. This mathematical formula applies only for a stirring shaft with two cross-arm stirrers. When more than two cross arms are used the speed .must be reduced below the calculated value to compensate for the increased turbulence. In conclusion, the agitation must be thorough but with controlled mild turbulence.

Commercial application of the process in an eleven foot tank at a speed of 9 r.p.m. has duplicated laboratory conditions. Speeds of 56 r.p.m., 36 r.p.m., 22 rpm. and 18 r.p.m. in the same commercial equipment with otherwise above defined methods of material addition, have resulted in failure of the process by premature gelling with the results indicated in Table V.

TABLE V.IT IFLUENCE.OF AGITAIION SPEEDS WITH TWO-ARM CROSS-STIRRER Lab. tests, 8" diameter Tank (with thorough controlled-mild turbulence obtained between 70-185 r.p.m.)]

Gel Condi- Time of Specific stirrer Speed, r.p.m. tions Gellin Surface,

Min. cmfl/g.

Normal. 12 71, 870

Premature 59,423

[Commercial plant tests, 11 diameter tank (with thorough controlledinild turbulence obtained between 4 AV r.p.m.)]

Normal 17 76.000 Premature 3 60, 629 -do 3 52, 484 do 3 51,800 do 3 36, Q61

Gel formation As discussed above under the heading Causticization reaction, the gelling phenomenon occurs in accordance with the invention from about 4 minutes to about 25 minutes after initial mixing of the reactants, dependent on temperature. By maintaining a controlled mild turbulence dnringmixing, the first appearance of the gelling phenomenon may be readily observed around the periphery of the surface of the reacting mixture. On the first appearance of gel formation, agitation is stopped and the gel is allowed to form, resulting in a gel-like solidity of the entire mixture.

Analysis of the gelled material at successive periods of 0, 5, 10, 15, 30, 45, and 60 minutes and 24 hours after gel formation has shown that the causticization reaction proceeds very rapidly for about fifteen minutes at which time about 90% of the Na+ has'converted from Na CO to NaOH and at which time the ultimate fine and uniform particle size of the CaCO has been substantiallyachieved. I Although the time thus required point at'approximately fifteen minutes whereat a relatively sharp change occurs in the rate of reaction, and

after which only slight differences are found .in the uniformity and size of CaCO particlesultimately produced.

Fig. 2 shows graphically the specific surface of CaCO I produced relative to the time period which the gel is one hour.

maintained after formation. The following data in Table VI, from which the graph of Fig. 2 was derived, was obtained by avprocess in accordance with the invention,

'wherein R was 1.2, R was 5.3 and the causticization was carried on at C.

Specific Surface (Blaine), emfi/gm.

Time

Accordingly, it will be seen that a critical point in the process of the invention is reached after maintenance of the gel for about fifteen minutes, and further that an optimum product in accordance with the invention is produced by maintenance of the gel for at least about The gel period is terminated at the desired time by vigorous agitation and the processes of thev infiltering. because of agglomeration.

vention are further conducted as discussed herebelow.

Filtration and washing .CaCO precipitates produced within the limits of all factors specified above consist of particles of uniform size of high specific surface capable of a highfilter rate. Recausticizing at an elevated temperature (boiling) with Na CO and refiltering of the precipitate results in poor This disadvantage has been overcome by further controlling the processes as follows: The gelled product is resuspended with vigorous agitation and filtered by vacuum. A wash solution of Na cO of 100 g.p.l. is.introduced over the entire surface of the filtered precipitate immediately upon re moval of the NaOH solution. When all the solution containing NaOH has been removed, this wash solution of N21 CO will react with the Ca(OH) remaining in the precipitate, which .was not originally causticized because of high OH concentration of the solution. The ternperatureof the wash Na CO being approximately that of the causticizing temperature .then produces CaCO from any remaining Ca(OH)2 of the same particle size as that 5 originally made in the causticizing process. Thehigh filtering rate then permits the excess Na CO to be removed at a rapidrate to Ca(OH) -free CaCO The rate at which NaOH (White liquor) and water pass through a'filter bed. is ameasure of the uniform produce a Na CO -free and 7 high surface CaCO produced by thisprocess. The highest :filtering rate hasbeen obtained with CaCO of the highest specific surface with a corresponding decrease in the filter rate with a decrease in specific surface. A

very drasticdecrease occurs on deviation of conditions beyond the scope of the present invention, as seen here below. 7

The filtering rate of CaCO precipitates produced by this process has been determined with a standard Oliver- United test filter; leaf as defined further above. The thickness of the filter cake picked up in a one minute interval-and the volume ,of filtrate filtering through the cake weremeasured; The, thickness of the filter cake corresponded proportionally to the quantity of white liquor filtered through the cake during the one. minute test.

beendetermined and correlated with the specific surface of the CaCO produced. As a matter of comparison,

like data is presented regarding suspensions produced by the process of the example of page 2 of the above cited 7 Rafton Patent, 2,062,255. These values are shown in Table VII.

TABLE VIL-COMPARISON OF SPECIFIC SURFACE (BLAINE) AND THE FILTER RATE OF CaCO; PRECIPI- TA'IES ON A STANDARD OLIVER-UNITED TEST LEAF. 5%lgglIfiITATE COLLECTED IN 1 MINUTE AT A VACUUM Caustlclzing gemperature, gperciflc filaikle wttlalre Filtrlate ur ace, gm. 0.

cmfllg. ness. in. ml.

20 i1gaccotiidlgg to process of 122a ven on 2 25in(acctrdlng to process of $346 van 1011 2 30 in(nectar-ding to process of {$2, ia :32 van )0 2 35m(accodir)1g to process of 2g, ven on ,0 l6 40 (accordlngto process of 34, 255 at 235 298 invention) 42. 940 V1 163 298 50 (But otherwise according to invention) 19, 201' %2 117 274 60 (But otherwise according r to invention) 18, 827 %2 123 286 70t(lnt ottherwise according 18 591 4 89 3 219 o'mven I011 a 'Rafton Patent Process 60,047 in 58.5 152 The choice ofa temperature of the wash water following the Na CO solution to remove the alkali is important in maintaining a high filtering rate. Commercial filtering operations suggest the use of hot water for the filtering operation which has been found to cause a shrinkage with a subsequent cracking of the filter. cake during washing with an accompanying decrease in the filtering rate. The presence of cracks or crevices in the filter cake permits wash waterto fiow through without properly washing the cake and the shrinkage in the filter cake prolongs the filtering cycle. Wash water near or slightly above room temperature causes only a very slight shrinkage of the filter cake and as long as the surface of the cake is covered with water, no cracks or crevices occur to cause improper washing. Therefore, water at or near room temperature, in the order of 20 C. to 40 C., is used for washing the final filter cake to more effectively remove'alkali from the precipitate without a decrease in the filtering rate and without the presence of crevices which would require prolonged washing.

Commercial application of process The need for a more uniform CaCO precipitate to be employed as a coating for certain high grade papers has prompted the commercial use of this process, It is realized that each typeof paper'pulp may require -a cific surfaces, produced by this process, to determine the carbonate best suited for this particular paper. The results of this investigation led to the finding that a CaCO having a specific surface in the order of 70,000 cm. /g. best suited for permeability, the high grade paper of one particular manufacturer.

A plant scale batch test was made in which 3120 pounds of CaO were slaked in 3000 gallons of weak liquor, water containing 4 g.p.l. NaOH, and the resulting Ca(Ol-l) suspension was reacted with 5500 pounds of Na CO in 3200 gallons of water. Causticizing was carried out at 25 C. in a tank 11' in diameter and 11 in height with a two-arm cross-stirrer operated at 56 r.p.m. As discussed further above, this speed caused premature gelling and ideal specific surface was not obtained. Tests were made at 36 r.p.m., 22 r.p.m. and 18 r.p.m., each producing premature gelling, resulting in a substandard carbonate requiring an excessive amount of adhesive for applying the carbonate to the paper and producing inferior gloss surfaced paper. A batch was produced at approximately 9 r.p.m. resulting in normal gelling in 17 minutes and producing CaCO having a specific surface of 76,543 cmfi/g. The adhesive demand of this carbonate was very satisfactory and the gloss very high which produced an excellent coating for the particular example of high grade paper mentioned above.

The commercial production of carbonate under the limitations set forth above will produce a carbonate of desirable characteristics for paper coating. The control of specific surface at other temperatures offers the opportunity to produce carbonates to suit various'other types of paper.

I Conclusion Data has been presented to show the reaction between Ca(OH)' suspensions and Na CO solutions to be very complex but at the same time capable of being carried out under specified conditions to produce a CaCO with a predetermined specific surface and having unusually uniform particle size distribution. The specific surface of the carbonate may vary from approximately 35,000 cmF/g. to approximately 120,000 cmF/g. to meet the needs of vari'ous'industries as pulp and paper, cosmetic, paint andextenders. The specific surface of a carbonate may be controlled by maintaining a series of conditions governing the growth of Ca(OH) crystals. The concentration of Ca(OH) the concentration of Na CO solutions, the weight ratio of water to the calculated solid materials present for the reaction, the temperature of the reaction and the rate of agitation all contribute to the successful productionof a CaCO of a specified specific surface. No single one of these conditions can be claimed to exclusively control this specific surface. It is a combination of these conditions contributing to the successful execution of the process.

Having completed a detailed disclosure of the preferred embodiments of my invention so that those skilled in the art may practice the same, I contemplate that variations may be made without departing from the essence of the invention or the scope of the appended claims. I

I claim:

1. .The method of making extra-fine CaCO of uniform particle size, generally substantially below one micron, comprising the steps of admixing a solution of Na CO having a temperature of from 20 to 40 C. with a suspension of fine Ca(OH) having a temperature substantially equal to the temperature of said solution, said Ca(OH) suspension having a concentration of from 175 to 194 grams per liter, the ratio of the weight of Na CO to Ca(OH) being from about 1.02 1.0 to about 1.40:1.0,

' completing said admixture prior to any gelling formation within the mixture of said solution and said suspension, said mixture having a total weight to solids weight ratio of from about 5.l:l.0 to about 5.8:1.0, thoroughly agitating said mixture with a controlled mild turbulence prior to said gelling formation, allowing said mixture to form completely to a gel, avoiding disrupting said gel for a period immediately thereafter of at least about fifteen minutes, disrupting said gel and forming a resuspension, and separating substantially completely by filtration the CaCO fine precipitate and NaOH liquor reaction products of which said resuspension consists, whereby a superior filter cake of fine, uniform CaCO is formed.

2. The method of making extra fine CaCO of uniform particle size, generally substantially below one micron comprising the steps of adjusting the temperature of a suspension of from to 194 grams per liter of fine Ca(OH) at a temeprature between 20 C. and 40 C., adding thereto a solution of substantially saturated concentration of Na CO free of Na CO -10H O having a solution temperature substantially equal to said suspension temperature, the ratio of the weight of Na C0 to Ca(OH') being from about 1.0:1'.0 to about 1.40:1.0, completing said admixture prior to any gelling formation within the mixture of said solution and, said; suspension, thoroughly agitating said mixture ,witha controlled, mild turbulence prior to said gelling formation, allowing said mixture to form completely to a gel, avoiding disrupting the gel formed by said mixture for a period of at least about fifteen minutes, thence disrupting said gel and forming a resuspension, and separating substantially completely by filtration CaCO fine precipitate and NaOH liquor reaction products of which said resuspension consists, whereby a superior filter cake of fine, uniform CaCO is formed.

3. The method of making extra fine CaCO of uniform particle size generally substantially below one micron, comprising the steps ofslaking CaO in an excess of water at approximately 100 0, thus providing a Ca(OH) of relatively high specific surface, forming therefrom a Ca(OH) suspension of, from 175 to 194 grams per liter .concentration, adjusting thetemperature ofisaid suspension at from 20 C. to 40 C.,-adding thereto a solution of Na CO having a concentration-of atleast 200 grams per liter and a temperature substantially. equal to said suspension temperature, the ratio of the weight of Na CO to Ca(OH) being from. about 1.0:1.0 to about 1.40:1.0,

6. The method of, claim 4' dwherein;the'wsolution of :Na CO is added to the Ca(OH) suspensionin substantially one-half of the time required for producing a gel.

; gelling is apparent.

7. The method of: claim 4;wherein.,said agitation is mantained at a substantially constantrdegree-from the first addition of Na CO at least until the first-indication of 8. The method of claim 7 wherein agitationis produced by the rotation of a two-arm cross-stirrer at a peripheral speed of from 140 to 390 feet per minute.

9. The method of claim 8 wherein the solution of Na- CO is added to the Ca(OH) suspension in substantially onehalf of the time required for "producing a gel.

10. The method of claim 4 wherein the filter cake producted therein is subsequently subjected to a second Na CO solution having a temperature substantially equal a to the temperatures of said first solution and said suspension and removing the remaining liquids, whereby the I excess Ca(OH) in said filter cake is converted to CaCO completing said admixture prior to any gelling formation within the mixture of said-solution and said suspension thoroughly agitating said mixture witha, controlled mild turbulence prior to said gelling formation, allowing said 7 mixture to form completely to a gel, avoiding disrupting 4. The method of making extra fine CaCO of uniform particle size, generally substantially below one micron, comprising the steps of adjusting thetemperature of a suspension of from 175 to 194 grams perliter of fine Ca(OI-l) at a temperature between 20 C. and 40 C., adding thereto a solution of Na CO having a concentration of at least 200 grams per liter and a temperature substantially equal to said suspension temperature, the ratio of the weight of Na CO to Ca(OI-I) being from about 1.0:l.0 to about 1.40:1.0, completingsaid admixture prior to any gelling formation within the mixture of said solution and said suspension, thoroughlyagitating said mixture with a controlled, mild turbulence prior to said gelling formation, allowing said mixture to form completely to a gel, avoiding disrupting the gel formed by said mixture for a period of at least about fifteen minutes, thence disrupting said gel and forminga resuspension, separating substantially completely-by filtration the CaCO fine precipitate and NaOH liquor reaction products of which said resuspension consists, whereby a superior filter cake of fine, uniform CaCO is formed.

5. The method of claim-4 wherein the said avoiding disrupting the gel is for at least about one hour, whereby an optimum fine, uniform CaCO is formed.

30 the gel formed by said mixture for a period of at least of a uniform particle size substantially equal to i the CaCO originally formed and collected in said filter cake.

11. The method of claim 10 wherein said filter cake is subsequently washed with wash water having a temperature of from 20 C. to 40C., whereby a rapid and complete washing may be had to provide a substantially pure CaCO of highly uniform fine particle size.

12. The method of making substantially pure, fine CaCO of uniform particle size, generally substantially below one micron, comprising the steps of adjusting the temperature of a suspension of from to 194 grams per liter of fine Ca(0H) at a temperature between 20 C. and 40 C., adding thereto a solution of Na CO .having a concentration of'at least 200 grams. per liter .about' 1.40:1.0, completing .said addition of Na CO solution" in substantially one-half of the time required for producing a gel, thoroughly agitating said mixture with a controlled, mild turbulence during the time from said first addition of Na CO until the formation of a gel occurs therein, producing said agitation by the rotation of a two-arm cross-stirrer having a peripheral speed of fr0m'140 to 390 feet per minute, allowing said mixture to formcomp-letely' to .a' gel, avoiding disrupting the gel formed by said mixture for aperiod of at least about fifteen minutes, thence disrupting said gel and forming a resuspension, separating substantially completely by filtration the CaCO fine precipitate and NaOH liquor reaction products of which said resuspension consists, subjecting the filter cake produced by said filtration to a second Na CO solution having a temperaturesubstantially equal to the temperatures of said first solution andsaid suspension, and washing the filter cake with wash water having a temperature of from 20 to 40 C.

References Cited in the file of-this patent UNITED STATES .PATENTS 

1. THE METHOD OF MAKING EXTRA-FINE CACO3 OF UNIFORM PARTICLE SIZE, GENERALLY SUBSTANTIALLY BELOW ONE MICRON, COMPRISING THE STEPS OF ADMIXING A SOLUTION OF NA2CO3, HAVING A TEMPERATURE OF FROM 20* TO 40*C. WITH A SUSPENSION OF FINE CA(OH)2 HAVING A TEMPERATURE SUBSTANTIALLY EQUAL TO THE TEMPERATURE OF SAID SOLUTION, SAID CA(OH)2 SUSPENSION HAVING A CONCENTRATION OF FROM 175 TO 194 GRAMS PER LITER, THE RATIO OF THE WEIGHT OF NA2CO3 TO CA(OH)2 BEING FROM ABOUT 1.0:1.0 TO ABOUT 1.40:1.0, COMPLETING SAID ADMIXTURE PRIOR TO ANY GELLING FORMATION WITHIN THE MIXTURE OF SAID SOLUTION AND SAID SUSPENSION, SAID MIXTURE HAVING A TOTAL WEIGHT TO SOLIDS WEIGHT RATIO OF FROM ABOUT 5.1:1.0 TO ABOUT 5.8:1.0 THOROUGHLY AGITATING SAID MIXTURE WITH A CONTROLLED MILD TURBULENCE PRIOR TO SAID GELLING FORMATION, ALLOWING SAID MIXTURE TO FORM COMPLETELY TO A GEL, AVOIDING DISRUPTING SAID GEL FOR A PERIOD IMMEDIATELY THEREAFTER OF AT LEAST ABOUT FIFTEEN MINUTES, DISRUPTING SAID GEL AND FORMING A RESUSPENSION, AND SEPARATING SUBSTANTIALLY COMPLETELY BY FILTRATION THE CACO3 FINE PRECIPITATE AND NAOH LIQUOR REACTION PRODUCTS OF WHICH SAID RESUSPENSION CONSISTS, WHEREBY A SUPERIOR FILTER CAKE OF FINE, UNIFORM CACO3 IS FORMED. 